12 Mar
Ask a crusher owner what they sell 20 mm aggregate for, and they’ll answer instantly. Ask what it costs them to produce one tonne, and there’s usually a pause.
That pause is expensive. If you don’t know your cost per tonne, you can’t tell whether a big discount to a contractor is smart business or quiet loss.
The simple formula
Cost per tonne = Total monthly production cost ÷ Total tonnes produced in the month
The formula is easy. The hard part is getting honest numbers into it.
Step 1: List every cost for the month
- Raw material: boulders bought or the cost of your own quarrying
- Diesel: loaders, excavators, DG sets, own trucks
- Power: electricity bill for the crusher
- Wear parts and spares: jaw plates, cone liners, screens, belts
- Explosives and drilling (if you quarry your own stone)
- Salaries and wages
- Maintenance and repairs
- Overheads: office, insurance, interest, depreciation
Step 2: Get the real tonnage
Use weighbridge dispatch plus closing stock change, not an estimate. Integrated weighbridge data makes this number trustworthy.
Step 3: Divide, and then break it down
Here’s an illustrative example (not real plant data):
| Cost head | Monthly cost (₹) | Per tonne (₹) at 20,000 t |
|---|---|---|
| Boulders | 30,00,000 | 150 |
| Diesel | 9,00,000 | 45 |
| Power | 6,00,000 | 30 |
| Wear parts & spares | 4,00,000 | 20 |
| Salaries & wages | 5,00,000 | 25 |
| Maintenance & overheads | 4,00,000 | 20 |
| Total | 58,00,000 | 290 |
Why the breakdown matters
The total tells you if you’re making money. The breakdown tells you where it’s leaking. In this example, diesel is 15% of cost, so a 10% fuel saving adds straight to profit.
The total tells you if you’re making money. The breakdown tells you where it’s leaking. In this example, diesel is 15% of cost, so a 10% fuel saving adds straight to profit.
Four ways to lower cost per tonne
- Cut diesel waste. Track litres per machine hour and per tonne.
- Reduce downtime. Every idle hour still carries salaries, interest and overheads.
- Improve throughput. More tonnes on the same fixed costs lowers cost per tonne fast. Tumkur Sands saw a 15% throughput lift with RokMixPro.
- Plan wear parts. Track replacement intervals and stop emergency purchases.
How RokMixPro helps
RokMixPro brings dispatch, fuel monitoring, purchases and expenses into one place, so the numbers for this calculation already live in your system rather than five registers. Explore our production management software.
FAQ
Should I calculate per product?
Yes, if possible. Finer products like M-sand often carry extra processing cost.
How often should I calculate this?
Monthly at minimum. Weekly is better during peak season.
Keep reading
- Crusher Software with Tally Integration: Let Your Accountant Breathe Again
- M-Sand Plant Management Software: Running a Sand Plant by the Numbers
- Your Plant in Your Pocket: The Crusher Management App for Owners
See RokMixPro running on your own plant data
RokMixPro is the crusher and mining ERP from M RANK, Bengaluru. Weighbridge integration, IP-camera photos on every slip, fuel monitoring, GST e-invoice and e-way bill, Tally integration and an owner app on Google Play, all in one system.
Book a free demo Chat on WhatsApp or call +91 98454 08134
